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F-13
DIAGRAMS
F-13
RANGER 250
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
CONTACTOR
CONTROL
SHOWN IN
"WELDING ON"
POSITION
WIRE FEED POWER
WINDING
42 VAC
C11
C10
42 VAC
FIELD WINDING
GND. SCREW ON LEFT
INSIDE CASEFRONT
D3
ARC CONTROL
10K
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
42
W3
CB7
15A
S1
9
7
W1
STATOR
WELD
WINDINGS
W3
W2
75
R1
76
77
278
CCW
OUTPUT CONT. POT
S3
2
GND-G
GND-D
GND-E
300 AMP
MODULE
SHUNT
50MV=400 AMPS
3
ROTOR
5A
3D
3A
5A
5B
5C
3
6
3E
6F
BLACK
50A
50A
20A
20A
BLACK
WHITE
WHITE
BLACK
BLACK
WHITE
BLACK
BLACK
SILVER
SILVER
STATOR AUX. WINDING
CONNECTORS VIEWED FROM INSERTION END
ELECTRICAL SYMBOLS PER E1537
FRAME GND.
5C
3A
3
6B
6
6B
CB1
CB2
CB5
CB6
6B
5B
J101
J102
J100
3E
6E
115/230V
10K
9
7
41
206B
206A
200A
201
201A
200B
32
3A
5C
+
HOUR METER
224B
5
5H
HEATSINK
208
4
279
BOTTOM GND INSIDE CASEFRONT
PCB 1
D1 - THREE PHASE BRIDGE RECTIFIER
W4
W5
W6
6
3
W10
2
1
P6-J6
16
8
1
9
P3-J3
9
1
16
PCB2 WELD CONTROL PC BOARD
Shunt
Sense/
Idler/
PWM
204S
206S
S6 MODE SELECTOR SWITCH
2A
13
5G
206S
204S
14
208A
208B
A
4
3
2
1
222
TIG
CC
PIPE
CV
220
218
214
8
CCW
R2
B7
B8
L1 CHOKE
W9
W8
3
6
WRAP TWO TURNS #3 &
#6 LEADS IN DIRECTION
SHOWN THROUGH
TOROID
3
6
RANGER 250G - WIRING DIAGRAM FOR CODE 10954 (KOHLER) 10953 (ONAN P220 OHV)
IDLER CONTROL
SHOWN IN
"AUTO" POSITION
S4
252
251
C3
800uf
150vdc
POSITIVE BRUSH CONNECTED
TO SLIP RING NEAREST
TO THE LAMINATION
WHITE
TERM.
L2
L3
TWISTED PAIR
W6
12 VOLT
BATTERY
-
GND-H
ENGINE
BLOCK
+
W11
(LOCATED BELOW
TERMINAL 2)
S1RUN-STOP
SWITCH
(SHOWN IN
RUN POS.)
12
7
6
1
1
2
L2, L3: RF CHOKES
16
9
8
1
CB8
TOP GND. SCREW ON
INSIDE OF CASE FRONT
LEAD COLOR CODE:
B=BLACK OR GRAY
R=RED OR PINK
W=WHITE
G=GREEN (W/YELLOW STRIPE)
FRAME GND.
41A
42A
15A
206A
21
S5
VOLTMETER
POLARITY
SWITCH
SHOWN IN
POSITIVE (+)
POSITION
G4284
31
32
GND-B
A
B
C
D
E
F
77B
21
75B
GND-A
41A
42A
76B
115VAC
CONTACTOR
77B
76B
WORK
75B
REMOTE
CONTROL
42VAC
GROUND
AMPHENOL 1
REMOTE
CONTACTOR
GROUND
AMPHENOL 2
CONTROL
J
A
D
C
H
B
K
E
F
G
I
208C
206C
BYPASS
FILTER
ASSEMBLY
5N
GND-B
4B
2B
2B
4B
208C
206C
206B
4A
77A
76A
75A
2A
4A
Battery Charge
Light PL2
9
1
16
8
7
1
12
6
P7 - J7
Output &
Arc Cont.
Mode
Select
P2 - J2
Engine &
Battery
Function
P1 - J1
Amphenol,
Model
Select,
Hot Start
C8
C9
25
23
Twisted
Pair
B4
B5
B6
B1
B2
B3
W5
200
77
76
75
277
279
278
277
214
218
220
222
215
252
251
77A
76A
75A
2
4
208B
260
261
13
14
23
260
261
224B
5G
210C
5K
5K
210B
200N
GND-K
GND-N
GND-E
GND-N
5K
5
5N
GND-G
GND-D
GND-C
GND-C
GND-B
GND-A
31
GND-J
GND-J
200N
R3
25
Key
Key
S2
START
BUTTON
224
5H
210A
R4
301
302
FRAME
GROUND
GND-K
GND. SCREW ON
FAN BAFFLE.
209
ENGINE COMPONENTS
B-
AC
AC
B
+
GROUNDING THIS CIRCUIT
STOPS THE ENGINE
IGNITION
MODULE
STARTER
1
2
3
P51
J51
OIL
PRESSURE
SWITCH
V
WHITE
R
FUEL
SHUTOFF
SOLENOID
ENGINE TERMINAL
BLOCK
4
224
210
REGULATOR
FLYWHEEL ALTERNATOR
212A
STARTER
CR1
SOLENOID
R
U
225
211A
221
229
211
228
225
229
228
212
210A210
210B
211
211A
221
5J
5J
IDLE
SOLENOID
215 210C
A.03
W10
W7